779 Washington St., Buffalo, N.Y. 14203-1396 U.S.A. • (716)856-2200 • Fax (716)856-1140 or (716)856-2068Manufacturers of Eastman Cloth Cutting and Cloth Spreading Machines

Website: www.EastmanCuts.comForm E-539

Technical Support:1-800-872-5595

WARNINGThis machine is equipped with a very sharpknife. Keep hands, arms, and hair away fromthe knife area at all times.

Misuse of this machine or failure to follow allsafety instructions on this machine and in theinstruction manual may result in seriouspersonal injuries.

THE EASTMAN ®

Operator’s Manual

Multi-PlyAutomatic Cutting SystemModel: MPC 5000

TM

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Congratulations

Congratulations in selecting an Eastman Multi-ply Cutter. With over 100 years of experience in the cutting room,Eastman is a world leader in cutting equipment. Every Eastman employee takes pride in each machine we buildand back it with unprecedented support. Our Technical Service department is made up of a dedicated staff of profes-sionals with years of experience installing, troubleshooting and servicing the Multi-ply Cutter. Each technician isfamiliar with all aspects of the machine including mechanical, electrical and software.Eastman Machine Company provides technical support and on-site service as required. We offer several affordableExtended Warranty plans that allow you to continue the superior technical support well after the machine is past ourstandard warranty. If you require on-site technical support or would like to schedule a preventive maintenance visit orneed additional training, please call our headquarters in Buffalo, NY to arrange for a technician.

Technical Support Eastman Machine Company 779 Washington Street Buffalo, NY 14203

Phone: 716-856-2200 Fax: 716-856-2068

Limited Warranty: Eastman warrants to the buyer that the equipment shall be free from defects in materialsor workmanship for a period of 180 days commencing on the date of invoice. Any goods or parts claimed by thebuyer to be defective must be returned to Eastman, freight charges prepaid,within the 180 day warranty period. IfEastman determines that the goods or parts are defective in materials or workmanship, Eastman’s sole obligationunder this warranty shall be, at Eastman’s sole option, to repair or replace the defective goods or parts or to providethe buyer credit equal to the portion of the purchase price allocable to the defective goods or parts. This warrantyshould not apply if defects are caused by product misuse or neglect, if the machine has been altered or modified bythe buyer or if other than genuine Eastman parts are used in the machine. THIS WARRANTY IS APPLICABLE TOTHIS PURCHASE ONLY. SELLER DISCLAIMS ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUD-ING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-TICULAR PURPOSE.

Limitation of Liability: Eastman’s liability to the buyer, and the buyer’s remedies from Eastman whether incontract, negligence, under any warranty or otherwise,shall be limited to the remedies provided in the foregoingLimited Warranty. In no event shall Eastman have any responsibility or liability to the buyer for (a) anyspecial,indirect, incidental, or consequential damages, including, but not limited to, loss of use, revenue, or profiteven if Eastman has been advised of the possibility of such damages, or (b) any claim against the buyer by any third

IMPORTANTThe purchaser must instruct all operators on the proper use of this equipment. All standard industrial safety measuresand equipment should be provided to protect the operator. Operators must be cautioned that improper or careless useof this equipment may cause personal injury. If you do not have qualified operators to instruct new persons, contactyour EASTMAN sales representative or EASTMAN factory direct.

Electrical connections and servicing to this equipment should be made by a qualified electrician who is familiar withapplicable codes and regulations. Disconnect this equipment from electrical power source before proceeding with anydisassembly for adjustment or repair.

Your Eastman Multi-Ply Cutter is designed to operate at a high rate speed. All personnel should be instructed towear safety glasses and stand well clear of the Multi-PlyCutter when in operation.

TM

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Table of Contents

General Presentation ..................................................... 4Over View ....................................................................... 5

Safety Information ............................................. 5General Safety Precautions ............................... 5Reference Manuals ............................................ 6Recommended Spare Parts List ........................ 6Software Solutions ............................................ 6Lifting/Moving .................................................... 6Electrical Component Specifications .................. 7

Familiarization ................................................................ 8Safety Zones and Stop Devices ......................... 8

Main Functional Units .................................................. 10Conveyor Frame assembly .............................. 10Vacuum System.............................................. 12Tool Head Assembly ........................................ 14Take-off Conveyor ............................................ 16Resealer Assembly ......................................... 17

Control Devices ............................................................ 18Take-on Push Button Station ........................... 18Gantry Controls ............................................... 20Take-off Conveyor Controls .............................. 22Key Board and Mouse Controls ....................... 22Variable Frequency Drive ................................ 22

User Interface Terminal ................................................. 23Program State ................................................. 23User Interface .................................................. 23Navigation Buttons .......................................... 23Function Buttons ............................................. 24Display Screens .............................................. 24

Table Layout ................................................................. 25Theory of Operation ...................................................... 28

Sharpener System .......................................... 28Blade Control .................................................. 30Cutting Process .............................................. 34SynqNet network ............................................. 35Intellicut .......................................................... 37Resealer .......................................................... 37Conveyor System ............................................ 38

Critical Cutting Parameters .......................................... 39Calibrations .................................................... 39Mechanical Alignment ..................................... 42Startup Procedure ........................................... 43Checks before Startup ..................................... 43Startup Instructions ......................................... 43Shutting down ................................................. 44Cautions / warnings ......................................... 44

Setup Procedure .......................................................... 45Setting up the Material on the Cutting Zone ..... 45 Setting up the Cut Parameters ....................... 46

Instruction for Aligning, Cleaning and Replacing Consum-able Parts .................................................................... 47

Replacement of Knife ...................................... 47Replacement of Sharpening Wheels ................ 50Replacement of Drill Rod ................................. 52Replacement of Guide Bushing ....................... 54Replacement of Vacuum Filter ......................... 56Replacement of Bristle Block .......................... 58Replacement of Polythene Rolls ...................... 59

Launching a Cut ........................................................... 59Calibration Procedure ................................................... 60

Order of Calibration.......................................... 60Checks before Calibration ................................ 60Tools Required................................................. 60

Maintenance operations to be carried out by operator .. 61Inspecting the Safety Devices ......................... 61Maintenance of User Interface Electronics ....... 63Maintenance of Gantry .................................... 63Maintenance of Cutting Surface ....................... 64Maintenance of Tool Head ............................... 65

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General Presentation

Eastman’s MPC-5000 Multi-Ply Cutting System is an automated reciprocating straight knife cutter, with conveyor,capable of cutting up to 5 cm (2 inches) of compressed material. Material is automatically conveyed from a spreadingtable to the cutting area where a polyethylene film automatically covers the spread to create an airtight seal. Eastman’smulti-ply system comes standard with an all-digital, network based motion control system, capable of monitoring itself aswell as reporting status alerts before faults or errors in operation occur. The real-time digital network and machine intelli-gence offers diagnostic, performance and reliability benefits. The robust MPC-5000 also features Intellicut™ knife controlsoftware and a six-stage vacuum turbine for superior material edge hold down. Optional features include a resealingdevice, a single or dual air drill, a blade chiller, a bristle cleaner, and a transverse table drive system.

The material to be cut is compressed on the bristle cutting surface by a six-stage vacuum turbine which is integrated inthe vacuum frame assembly. The silencer for the unit is also integrated within the vacuum frame assembly. The vacuumdrive motor is cooled by an auxiliary fan motor. A vacuum filter is accessible by the operator and includes a warningsystem to indicate when the filter needs to be cleaned or replaced.

The Gantry assembly is driven along the x-axis by dual motors located at each end of the gantry tube. The Y-carriage issupported on the gantry and is driven along the Y-axis by a single motor contained within the Y-carriage. The toolheadassembly is attached to the Y-carriage and contains the knife reciprocating drive, the sharpener stones, the theta-axismotor, and the optional drills and chiller assemblies. All electronics for driving the gantry and toolhead devices are locatedadjacent to the component being driven or controlled. The electronics are interconnected throughout the system by aSynqNet network cable. The gantry also features a touch screen display, joy stick control, presser foot pressure controland tool on/off switch.

A Take-Off-Conveyor assembly is provided for removing cut pieces from the table without disturbing the conveyor vacuumseal. This conveyor is electronically synchronized with the bristle conveyor surface during cut operations.

An electronic enclosure, located under the take-off conveyor, is also contained within the vacuum frame assembly.Included within this assembly are the transformers, relays, circuit breakers, and filters for the entire system. The con-veyor drive, take-off conveyor drive, and main CPU are also contained within the electronics enclosure.

The operator controls and manages the cutting process using the Eastman operating control software “eCut™”. The“eCut™” software is a powerful, flexible and windows based program residing in the main CPU.

SynqNet is an all digital motion network specifically designed for high performance motion applications. SynqNet canperform all system level control and use one network for supporting motion control and Input / Output. SynqNet providesthe facility of creating a motion network with centralized control and distributed hardware, which allows placing discreteInput / Output modules in more convenient locations for shorter cable runs.

SynqNet also makes it possible to troubleshoot the machine remotely. An operator can examine the status bits of themachine through software to get a clear indication of the error status for quicker maintenance and repair. SynqNet en-sures that communication is maintained between the motion controller and all drives on the network.

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Over View

Safety Information

Throughout this manual, safety information is presented by the use of the terms WARNING, CAUTION, ELECTRI-CAL HAZARD, and NOTE. These terms have the following meanings:

WARNINGA warning contains critical information regarding potential safety hazards that can occur during proper use or mis-use of the machine. Failure to follow these procedures may result in serious personal injury to the user.

CAUTIONA caution contains instructions for the use or maintenance of the machine. Failure to follow these procedures mayresult in damage to the machine.

ELECTRICAL HAZARDAn electrical hazard calls attention to a procedure, practice, or the like, which, if not correctly performed or adheredto, could result in personal injury. Do not proceed beyond an Electrical Hazard.

NOTEA note provides additional information or tips on the operation, maintenance and/or trouble shooting of the machine.

Safety and Indemnification

During the life of the machine, the purchaser agrees to provide to all machine users (including its own employeesand independent contractors) all relevant safety information, including warning labels and instruction manuals. Thepurchaser also agrees to maintain the safety features and working condition of the machine, and to adequately trainall users in the safe use and maintenance of the machine. The purchaser agrees to defend, protect, indemnify, andhold Eastman Machine Company and its subsidiaries harmless from and against all claims, losses, expenses,damages, and liabilities to the extent that they have been caused by the purchaser’s failure to comply with theterms and instructions of this manual.

General Safety Precautions

WARNING

• This machine is equipped with very sharp and dangerous tools. Keep hands, arms, and hair away from the cuttingarea and drive system at all times. Use of Safety gloves, glasses, and appropriate clothing may prevent seriouspersonal injuries.

• Disconnect the power and pneumatic supplies to the machine when it is not in use or during routine maintenance,including cleaning and lubrication.

• The purchaser must instruct all operators in the proper use of the machine according to the instructions in thismanual. This training must include instruction on the potential safety hazards arising from the use or misuse of themachine. In addition to such training, the purchaser should provide written work instructions as necessary to ensurecorrect use of the machine for specific cutting and spreading applications.

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• Do not modify this machine or disable safety features. Unauthorized modification may result in serious personalinjuries to the user. Electrical connections to this machine must be made by a qualified electrician familiar withapplicable codes and regulations.

• Safety labels must be kept clean and legible at all times. Call the Eastman Machine factory to order replacementlabels.

Hearing protection devices are recommended for prolonged exposure to noise of the blower. Noise data isavailable at Eastman Machine.

The Eastman Multi-ply Automated Cutting machine has been inspected and tested at the factory prior to shipment.The Multi-ply machine is shipped partially disassembled and requires some assembly and setup before operationcan take place. Refer to the installation guide for installation instructions. To get the best performance, familiarizeyourself and all operators with all functions and adjustments of this equipment. Refer to the Multi-ply cutter servicemanual. Before any operation takes place it is important carefully read and follow the instructions in these referencemanuals.

Reference Manuals

E-538 .....MPC 5000 Service Manual E-538 .....MPC 5000 Illustrated Parts List E-540…MPC 5000 Installation Manual

Recommended Spare Parts List

Refer to Appendix A

Software SolutionsEastman offers a wide variety of software for various applications. Please consult with your nearestEastman Representative or the Eastman Factory directly, for more information.

Lifting/Moving

The lifting and moving of this system must be in accordance with the installation requirements. Failure toadhere to these installation requirements may cause injury to persons or hinder machines performance.Refer to installation manual.

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* Note: The Control Power provides power to the computer, gantry, conveyor and DC power supplies. No additional electrical connections are required.

Electrical Component Specifications

Specifications

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Familiarization

Safety Zones and Stop Devices

Pause Buttons and Stop Discs

The yellow button on top of both sides of the gantry will pause the machine when pressed. The machine will also gointo a pause state if a stop disc on either side of gantry is pushed Activating the pause function will execute acontrolled stop of the cutter, while the machine remains fully powered. After releasing the pause button or resettingthe stop discs and pressing NEXT on the UIT keypad, the cutter will resume cutting the work in progress. PressingABORT will cancel the job. The cutting tool head can be moved using the joystick while in pause mode and thenresumed.

Emergency Stop Buttons

There are red Emergency Stop buttons located on each side of the gantry as well as on all four corners of the table. Pressing any of the Emergency Stop buttons will execute a controlled stop of the gantry before removing all powerto the motors. To release an Emergency Stop condition, pull out the Stop button and then press the ABORT key onthe UIT keypad or click the mouse on the E-Stop window. Emergency stop mats and light curtains are also availableas an option. Please consult the factory for pricing and availability.

Stop

Stop

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Multi-Ply Cutting SystemFamiliarization

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Main Functional Units

Conveyor Frame assembly

The conveyor drive is enclosed by an air tight structural frame. The complete structure is continuous seamwelded for structural and air tight integrity. All critical surfaces are machined and finished to precision tolerances.All side panels are made of steel sheets which are powder coated for longevity. Each panel is removable forservice and maintenance of machine.

The conveyor cutting surface consists of Eastman bristles, extruded aluminum slats, bristle end clamps, con-veyor drive chain, and conveyor bed. The Eastman bristles and bristle clamps are arranged on an aluminum slatto create the continuous cutting surface.

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Vacuum System

The vacuum system is located at the front of the conveyor frame. This system consists of a vacuum blower, air filtersystem, silencer and exhaust duct. The vacuum blower has an integrated 30 HP motor with a six stage compressorwithin a single housing. This allows a more compact system without having to use belt, pulleys or any other separatedrive mechanisms.

The vacuum blower is intended for holding the material on the conveyor bed during the cutting operation and advance-ment of material. The vertical exhaust duct which is mounted on the side of the machine is responsible to direct thewarm air away from the operator. This also helps to decrease the audible noise observed by the operator. The exhaustduct support tube can also be utilized as a power mast for bringing power and air to the machine.

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Gantry Assembly

The gantry assembly consists of main tube assembly, operator side plate assembly, non-operator side plate assemblyand the y-carriage assembly. The gantry assembly is a mobile unit that provides the controlled motion in ‘X’ and ‘Y’directions.

The gantry assembly contains one motor at each end of the main tube assembly. These motors are synchronized andmove the gantry along the X axis on the guiding rails and linear racks located on both sides of the conveyor frameassembly. The cutting tool head is fixed on the y-carriage which slides on the main tube assembly. The motor formoving the toolhead along the Y axis is located on the Y-Car assembly.

The gantry assembly contains a pause and emergency stop button on the operator side plate. The non-operator sideplate contains a tool on/off switch, an emergency stop button, a joy stick control, a touch screen display and othercontrols which are explained in the control devices section.

Electronics and power for controlling and monitoring the motors and sensors are contained within their respectiveOperator Side Gantry, Non-Operator Side Gantry, and Y-Car assemblies. The electronics are connected to the maincontroller through the SynqNet network cables.

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Tool Head Assembly

The tool head houses a network of electromechanical, electrical sensors, and pneumatic components working togetherto accurately cut and mark materials as required by the operator. The tool head is capable of cutting, drilling andmarking materials. The network of electromechanical, electronic sensors and pneumatics are controlled and monitoredthough the SYNQNET system.

The electromechanical motors are brushless with encoder feedback to ensure smooth, guided and precise motion. Theencoders provide a finite level of position and motion feedback allowing the control system software to respond to anycircumstances in material cutting. These motors are utilized in both the main reciprocating drive as well as the theta(knife direction) control.

Electrical position and load sensors are constantly measuring and monitoring the cutting actions being performed. Theconstant flow of information through SYNQNET ensures the accuracy of the cut by monitoring and responding to thechanging information. Sensors are placed to monitor and control the position of the pneumatics to ensure safe andaccurate motion of the cutting knife.

Monitored Pneumatic cylinders are used in the assembly to facilitate the required movements. The Pneumaticsprovides motion of various required movements such as knife plunge, activation of sharpening, drilling features, andpresser foot control. The presser foot is passively controlled by the operator at the operator side plate assembly bymeans of the Presser Foot Vacuum Control Valve and Indicator.

The rotating toolhead assembly houses the knife guiding system, consisting of upper, lower, and middle guides. Italso houses the sharpener assembly which contains 4 round grinding stones for alternatively sharpening each side ofthe blade. The sharpening stones are driven by the theta motor during the sharpening cycle.

The lower knife guide is located at the base of the presser foot. This guide system provides precision support for theknife while cutting. Pressure transducers, used by the Eastman Intellicut feature for sensing both side loads andforward cutting loads, are located within the lower knife guide assembly. The electrical wires connecting the Intellicutsignals pass thru the slip ring assembly.

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Take-off Conveyor

The take-off conveyor can be found above the vacuum system. Its primary function is to convey the cut material fromthe conveyor frame to the take-off station. The drive motor is synchronized with the conveyor motor during cutting. Aseparate control is provided for advancing the take-off conveyor without moving the cutting conveyor.

The system consists of primary frame structure, conveyor belt, tension rollers, and drive motor along with a drive belt.

The take-off conveyor has drive covers for operator protection. These covers house the drive mechanism along with anergency stop button is integrated into the entire machine control logic to halt all the machine operations in case ofemergency. The jog button allows the operator to as required. These features are found on both sides of the machinei.e. on the operator side and non-operator side.

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The Resealer mechanism automatically maintains a plastic cover over previously cut portions of material for thepurpose of controlling and maintaining the vacuum pressure.

The mechanism consists of an application roller, automatic windup roller and plastic materials. Both the applicationroller and the wind up roller are designed to maintain a constant tension of plastic material and the automatic rewindwhen required. The application roller is mounted to the gantry and the windup roller is mounted to the frame structure.

Resealer Assembly

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Control Devices

Take-on Push Button Station

The push button station is available on both the operator side and non-operator side of the multi-ply machine.This push button station is located on the Overlay Resealer tower. This station is a rectangular box which hasfour push buttons.

The emergency stop (E-stop) is a red button located on the top of the box. Pressing this button will stop themachine operation immediately, removing all power to motor amplifiers and motor controls. When the button isdepressed it glows a red color. To return to an operational mode the button must be pulled up manually and thenfollowed by resetting the software at the computer. This applies to all E-stop buttons available on the machine.An E-Stop will force the active cut job to be aborted.

The yellow button which is the first button in front of the box is the pause button. Pressing this button while themachine is cutting the material will pause the cutting operation temporarily. To resume cutting the operator canpress the green start button which is the second button from top located at the front of the box, or follow direc-tions on either the UIT or control monitor. The gantry and tool head can be moved following a pause and thenresumed for continuing with an active cut file.

The green button which is the second button in front of the box resumes the machine operation after a pause.The next button on the UIT performs the same function as this button.

The black button in front of the box which is at the bottom most is used to “Jog” the conveyor cutting surface sothat material would be advanced on the table. When the button is released the conveyor cutting surface motionwould be halted. The main function of this button would be to load and unload material from the conveyor cuttingsurface.

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Gantry Controls

The gantry has controls both on the operator side and non-operator side.

Non-operator Side

On the non operating side we can find two push buttons namely the pause button and the E-stop button. Thesebuttons perform the same actions as E-stop and pause buttons which are located on the push button station. Fordetails please refer to push button station.

The non-operating side also has stop disc controls. Pushing the disc from either side will pause the cutting action.When the stop disc is pushed to either side and when the machine enters the pause state the pause push buttonilluminates to alert the operator that the pause disc has been engaged. To resume the cutting operation the stop discsmust be returned back to center, detented position. The operator can feel the disc moving to center, detented positionand visually confirm when the pause push button light turns off. Refer to operator side controls to resume cuttingoperation.

Stop Disc

Stop Disc

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Operator Side

The operator side control has the following functions namely, tool on/off switch, E-stop push button, pause pushbutton, joy stick controls, touch screen display, pressure foot pressure regulator, pressure gauge and also the stopdiscs.

The tool on/off switch is used to control the activation of the cutting tools. It should be turned to on position in order tocut material during normal operation. Turning off the tool on/off switch suspends tool operation but still allows gantrymovement. The E-stop and pause push buttons perform the same actions as E-stop and pause buttons which arelocated on the push button station. The joy stick is used to move and position the gantry in X and Y directions. Thereare 3 speed settings which can be selected by the operator on the touch screen to move the gantry . The up the laserpointer with the material prior to cutting.

The touch screen is used to perform various operations. Please refer to topic “Detail Description of Machine Control”

The presser foot pressure regulator controls the pneumatic pressure of the presser foot against the cutting material.The actual pressure can be observed on the pressure gauge which is located below the regulator. The pressureshould be set to maintain the presser foot in contact with the material in order to keep the lower knife guides posi-tioned for cutting. Excess pressure may cause either the plastic overlay or cut materials to move.

The operating side also has stop disc controls and they perform the same operation as that of non-operator side. Toresume cutting operation the operator must perform one of the following three actions i.e. press the “Next”button at one of the push button stations, or follow directions on the main computer monitor. When resuming, thecutting tool will be positioned at the exact coordinate it was paused, and then continue to cut the remainder of themarker.

Stop Disc

Stop Disc

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Take-off Conveyor Controls

The take-off conveyor has push button control stations on both operator and non-operator side. This push button stationconsists of E-stop button, Jog button. The E-stop button performs the same function as in push button station. The Jogbutton when pressed moves both the cutting conveyor belt and take-off conveyor belt simultaneously so that the cutmaterial can be moved forward as required.

Key Board and Mouse Controls

The key board, mouse and monitor are located on a stand on the operator side of the table. They are used to openfiles, cut files, edit files, set machine and job parameters, and control cutting operation.

Variable Frequency Drive

The operating system for the multiply cutter incorporates the use of a variable frequency drive (VFD) to manage andcontrol the vacuum deliverable to the machine. The VFD unit should be mounted in a convenient location next to, oron, the multi-ply machine. The VFD can be operated manually by the operator or automatically controlled through theEasiSuite software.

The use of the VFD gives the machine greater flexibility in types of material cut and makes the machine efficient inpower consumption.

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User Interface Terminal

The User Interface Terminal (UIT) is an operator’s console mounted on the moving gantry of Eastman’s automatedcutting table. The UIT consists of a color display with touch screen capability and a set of ten programmable soft keybuttons.

The UIT software presents a number of different display screens to the operator. Each screen contains commandbuttons, text input or edits boxes and message fields that permit the operator to monitor and control table operations.The ten soft keys (five along each side of the display) have fixed functions assigned to them. These soft key functionsare generally always available to the operator, regardless of the currently displayed screen. However, one or more softkeys may be temporarily disabled by the UIT’s operating software during specific system states or operating condi-tions.

The UIT acts as a remote terminal for a PC based server program which actually performs all of the system controlfunctions. The UIT has an Ethernet port that allows it to be connected to and communicate with the server program.

Program State

The UIT software can be in one of three states: initialization, operational or sleep.

The software enters the initialization state anytime if there is no Ethernet connection with the PC server. This will bethe case each time the UIT is powered up and also any time that the Ethernet connection to the PC server is brokenfor any reason. During the initialization state, the software attempts to connect to the PC server and, once a connec-tion is established, performs all required hardware and software initialization. The only screen displayed during theinitialization state is the Initialization Mode screen.

When the initialization state terminates, the UIT software enters the operational state. It is during this state that theoperator performs all system monitor and control functions. All screens other than the Initialization Mode screen maybe accessed when the UIT is in the operational state.

If there has been no soft key or screen input from the operator or no message received from the PC server for at least3 minutes, the UIT enters the sleep state. The only difference between the operational state and the sleep state is thatthe UIT’s screen is blanked and the display backlight is turned off during the sleep state. This is intended to extendthe life of the display.

User Interface

The operator interacts with the UIT through a user interface that consists of ten soft keys and a 320 x 240 pixeldisplay with touch screen capabilities. The operator uses this user interface to obtain information about the currentsystem status and to execute system commands or alter system settings.

Navigation Buttons

The UIT has ten soft keys or buttons. Five soft keys are arranged vertically along each side of the display screen. Thefunction of each soft key is determined by the UIT software. The function of each soft key remains fixed throughoutexecution of the software but one or more soft keys may be disabled by the software at times when its function is notapplicable or appropriate.

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The five soft key buttons along the left edge of the UIT screen are used for navigation between various UIT displayscreens. There are no PC server message commands associated with any of these buttons. The soft key buttons onthe left edge of the UIT are, from top to bottom:

Cutting – displays the Cutting Mode screen Tools – displays the Tools Mode screen Calibration – displays the Calibration Menu screen Setup – displays the Setup Dialog screen

More – displays the More Menu screen

Function Buttons

The five soft key buttons along the right edge of the UIT give the operator quick access to frequently used tableoperating functions. Each of these buttons is associated with a PC server message command which is given inparentheses at the end of each buttons description. The soft key buttons on the right edge of the UIT are, fromtop to bottom:

Zero – sets the current pointer tool position as the local coordinate system origin. (ZERO)Next – context-dependent function that starts or resumes an action. (NEXT)Enter – context-dependent function that completes a response or confirms a request. (ENTER)CheckRef. – initiates the process of locating the global coordinate system origin on the table.(CHECKREF)Abort – context-dependent function that abnormally or prematurely terminates an action.(ABORT)

These ten soft key functions are always available to the operator, subject to certain specific restrictions asdescribed in display screen menu.

Display Screens

The UIT software displays a number of different controls such as command buttons, scroll buttons, text labelsand a multiple line text data grid to inform the operator of the current system status and to allow the operator toexecute system commands or alter system settings. Please refer to the topic “Detail Description of MachineControl” for more details.

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Table Layout

The following diagrams identify the following machine location definitions:

X-axis left table limit (operator and non-operator side):It is the negative distance from X Home position to the left mechanical limit of the table

X-axis right table limit (operator and non-operator side):It is the positive distance from X Home position to the right mechanical limit of the table

Table Left:It is the negative distance from X Home position that determines the bite length

Table Right:It is the positive distance from X Home position that determines the maximum cutting position

X Home Position:It is the X distance from Table Zero

Table Top:It is the distance from Y home position to the maximum positive cutting position set by the user by defining the cuttingwindow

Table Bottom:It is the distance from Y home position to the maximum negative cutting position set by the user by defining the cuttingwindow

Table bite cutting region:It the boundary formed by the table left in the X direction and the summation of Table Top and Table Bottom in Y direc-tion. Both put together forms the bite length or bite cutting region

Y-axis upper table limit:It is the positive distance from Y home position to the upper mechanical limit of the table

Y-axis lower table limit:It is the negative distance from Y home position to the lower mechanical limit of the table

Y Home Position:It is the Y distance from Table Zero

Table Length:The table length is the distance from X-axis left table limit to X axis right table limit. Table length is the physical pre-defined factory setting length and this cannot be changed or altered.Table Width:The table width is the distance from Y-axis lower table limit to Y axis upper table limit. Table width is the physical pre-defined factory setting width and this cannot be changed or altered.

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wheels are connected through an O-ring belt and driven by a planetary gear system. The planetary gear system con-sists of an outer gear, which turns on the knife axis by means of the theta motor, and an inner gear, which is coupled onits own shaft to the o-ring belt driving the sharpener wheels. When both gears are free to turn, there is no relativemovement of the inner gear to the outer gear, and the o-ring shaft does not rotate. When the sharpener brake is en-gaged, the outer planetary gear is stopped, and the inner gear then rotates, driving both the o-ring drive and the sharp-ener CAM. During the sharpener CAM rotation, the CAM face forces the CAM pin out of the detent position, enabling thesharpener wheel housing to rotate the two sharpener wheels towards the edge of the knife. The force applied to theknife is controlled by a friction clutch at the bottom of the inner gear shaft.

Sharpening continues for a number of cycles programmed by the operator. At the completion of the total number ofsharpening cycles, the theta motor rotates the planetary system in the opposite direction, until the detent pin locks thesharpener wheel housing in its neutral position. The brake then disengages and the sharpening cycle ends.

The cycle can be repeated to sharpen the other side of the knife by rotating the theta motor in the opposite direction.

Knife Penetration System

Four grinding wheels are used to sharpen the knife with two wheels on each side of the sharpener housing. These

Theory of Operation

Sharpener SystemSharpener Operation

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Setting Wear Rate for Sharpener

Every time the knife is sharpened some amount of material is removed on the blade. To compensate for this, theLEAD parameter in the MACHINE SETTINGS is modified continuously based on the new calculated position ofthe leading edge. The maximum allowable wear for the blade can be set in the software.

The following variables will affect the amount of material removed from the blade on each sharpening cycle:

• Friction setting of clutch.• Rotating speed of stone.• Sharpening time.• Grit of the stones.• Knife reciprocating speed.

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Blade Control

Knife Guide System

The primary knife guide consists of a guide tube which provides a smooth and precise linear bearing support for theknife coupler/clamp in both the sharpening and cutting positions. It is important to maintain the guide tubelubricated with grease at all times.

Three additional guides are also provided. The Upper and Middle Knife Guide is used to guide the knife in both thecutting and sharpening cycles, whereas the Lower Knife Guide is used solely to guide the knife during the cuttingoperation only.

The upper knife guide has two cylindrical rollers which rotate on needle bearings. A throat plate, located above thetwo rollers, provides a guide for the operator to feed the blade into the guide system. The front edge of eachcylindrical roller contains a conical surface which engages the beveled edges of the blade preventing any forwardmotion of the blade, while also providing rigid support when rotating the blade.

The Middle Knife Guide contains hardened side and back plates for maintaining the position of the blade at thecenter of the four grinding stones.

The lower guides are subjected to the most severe loads during the cutting operation. These rollers must thereforebe maintained clean, well lubricated, and properly adjusted at all times. The lower knife guide contains four siderollers and rear roller. The lower knife also houses the intellicut sensors and load cells.

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Knife Penetration System

While performing the cutting operation on the material the knife tip must be in the bristle at all times. The bottomstop is used to adjust the location of knife when the knife is in cutting position. At the top of the stroke the knifeshould not leave the bristle surface.

Extremes:

Knife too high – Doesn’t cut the last layer of materialKnife too low – Will damage the bristle or may twist and cut the bristle

Knife Lift adjustment (for sharpening)

While performing the sharpening operation the entire cutting edge must be within the grinding wheels at all times.The upper stop is used to adjust the location of knife when the knife is in the sharpening position. During sharpening when the crank shaft housing is at the top of the stroke the knife should not project outside the lower grindingwheel.

Extremes:

Knife too high – Doesn’t sharpen the upper edge of knife (less than 5cm of blade will be available for cutting).Knife too low – Doesn’t sharpen the lower edge of knife (bottom layers of material will .

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Cutting Process

Cutting cycle

• The operator selects “cut this file” option in eCut menu.

• The vacuum system turns on.

• The operator types “Zero” or selects “Zero” in the UIT.

• Then Theta turns to home position.

• The operator types “Next” or selects “Next” in the UIT.

• The Knife reciprocation turns on.

• The knife undergoes a sharpening cycle.

• The system checks the vacuum level.

• The knife moves to the laser pointer position.

• Theta turns to its initial cutting position.

• The presser foot moves down to the material surface.

• The knife plunges into the material.

• Now the cutting begins.

Setting cut speeds (using seed number)

On hold for now.

Cutting notches

On hold for now.

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SynqNet network

The Multi-Ply Cutter Architecture is based on a distributed motion control network. This means that all communicationto and from motors, inputs and outputs occurs over a ring topology network. As can be seen from the related graphic,where the network starts and ends at the computer. Starting with cable S1 we leave the computer and visit every node(motor, inputs and/or outputs) on the network and return back to the computer. This provides two paths to each nodeallowing a built in communication redundancy. If one of the noperable, the machine can still communicate with thecomputer successfully. It will also alert the operator about the existing problem and still be able to cut files normally.

In addition to the redundant network, the major cables for each axis of motion are color coded based on their functionas follows:

Network "S" Cables - These cables come in two colors Purple and Black. The Purple Network cables are continu-ous flex rated and are found at points of motion on the machine. The Black Network cables are standard flex and arefound along the stationary network paths.

Power "M" Cables – These cables are Orange in color and provide power from the amplifiers to the motor.

Feedback "F" Cables – These cables are Green in color and provide feedback from the Hall Sensors and Encoder onthe motor to the amplifier.

Control "I/O" Cables – These cables are Grey in color and connect the amplifier to axis specific inputs and outputson the Custom I/O Block.

If the operator has access to Microsoft Corporation’s Visio program, he can open the Multi-Ply machine graphic on acomputer. Once open, if the operator moves the mouse over any component on the graphic, a pop-up box will tell the

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Intellicut

Intellicut including electronics and slip rings – on hold for now.

Resealer

The resealer is a mechanism designed to ensure that maximum cutting vacuum pressure is maintained. This isachieved by temporarily applying a reusable plastic film to cover already cut material on the table. This mecha-nism consists of two major components; namely the application assembly and the windup assembly.

The application assembly is mounted to the Gantry side plates and travels along with the gantry. This assemblydispenses and rewinds the resealer plastic on the cut surface dependent on the gantry movement.

The windup assembly is mounted rigidly to the take-off end of the frame structure. This assembly winds up theplastic overlay when the conveyor cutting surface advances and the plastic overlay is no longer held by vacuum.

Internal to each of these assemblies there is a rotary spring which provides tension and winding motion. Duringoperation it is required that the gantry go to the absolute zero table location. This allows the application assem-bly and the windup assembly to transfer or balance the plastic overlay so that each has sufficient amount ofplastic overlay.

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Conveyor System

Chain drive

The cutting surface consists of multiple bristle/slat assemblies coupled to a drive chain to form a “bristle belt”. on the main drive shaft. The main drive shaft is directly coupled to a motor/gearbox assembly by having the shaft gothrough the hollow gear box.The motor is a brushless dc servo motor driven through the SynqNet network.

The primary drive sprockets are keyed to the drive shaft and when the rotation of drive shaft is applied creates constant,precise and linear movement of chain through the sprockets. The drive shaft is supported by two bearings on either sidefor smooth and constant motion and to support the load of system.

There is also a pair of secondary or driven sprockets which in turn are keyed to driven shaft. The main purpose of drivenshaft is to provide tension in the system and also help for alignment control. The operator side and non operator sidedrive chains are synchronized by the drive mechanism. The aluminum slats are secured to the drive chain by fasten-ers. Additionally the aluminum slat is supported vertically by a precision roller bearing surface and laterally by a systemof chain guides.

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Calibrations

The following parameters are critical for cutting. The operator must ensure that these are calibrated correctly beforestarting the cut.

Theta offset

The theta offset is the theta compensation for tool misalignment so that the knife can cut parallel to the direction oftravel

Critical Cutting Parameters

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Normal offset

The normal offset is the side by side blade compensation to correct for misalignment of the knife to the machine cuttingposition.

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Blade Lead

The Blade Lead setting is used to adjust the leading edge travel of a knife at the end of a cut, thereby controlling overcut.

Blade Trail

The Blade Trail setting is used to adjust the trailing edge travel of a knife at the starting of a cut, thereby controlling overcut .

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The below mentioned items are critical for alignment, please refer to service manual for detail description

• Knife guides.• Gantry alignment and leveling.• Toolhead alignment and leveling.

Mechanical Alignment

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Startup Procedure

Checks before Startup

• Ensure that the table surface area is free from any obstructions.

• Ensure that all safety covers (Tool head cover, Gantry cover, side panels) are secured.

• Check that all the doors (electric cabinets, computer cabinets) are closed.

• Make sure that no one is standing inside the safety zone.

• Ensure that the emergency stops are disengaged and the stop dics are in their neutral positions.

• Ensure that all cables are connected and locked. Refer to the installation manual for cable connections.

Startup Instructions

• Turn on power to the VFD using the disconnect switch provided by your facility. Turn on the VFD.

• Turn on power to the machine using the disconnect switch provided by your facility.

• Turn on the compressed air supply using the disconnect switch provided by your facility.

• Τurn on the Multi-Ply Cutter main power switch located under the take off conveyor on operator side.

• Open the front cabinet cover of computer and turn on the main power switch.

• Start the eSuite software.

• Now find the Home switches and Limit switches as described below.

• When you start the eSuite software a dialog box displays the message “Do you want to look for homeswitch positions”. Click the Yes button.

WARNING

• Responding with “yes” will cause the gantry and tool head to move. Ensure that there are no obstructions to themotion.

• A second dialog box displays the message “Do you want to check table limits”, Click the Yes button.

WARNING

Responding with “yes” will cause the gantry and tool head to move. Ensure that there are no obstructions to themotion.

At the completion of the above startup procedure, the toolhead and gantry will be located at the home position.

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Shutting down

• Exit the eSuite software application.

• Shut down the computer using start / shut down / windows commands.

• Turn off the main power switch located under the take off conveyor on operator side.

• Turn off the VFD power by pulling the handle of disconnect to the off position.

• Turn off the machine power using the disconnect switch provided by your facility.

• Turn off compressed air supply using the disconnect switch provided by your facility.

• Execute proper lock out / tag out procedures as required by your facility.

Cautions / warnings

• Keeps hands away from the cutting area.

• Ensure that there is sufficient clearance on the operator and non-operator side.

• Turn off power before maintenance.

• Do not perform maintenance alone.

• Check the electrical cables for any damages.

• Don’t operate this machinery unless you receive formal training.

• When the air supply is off the tool head and drill will drop down, don’t move the gantry without air supplyunless the knife is removed else it may result in damage of bristles.

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Setting up the Material on the Cutting Zone

• Ensure the Multi-Ply cutter is powered on, and initialized using EasiSuite software

• Spread material on the spreading table, Underlay paper is normally required under materials when cutting.The underlay paper can be placed on the spreading table prior to spreading, or can be automaticallyinserted at the cutting table using Eastman’s automatic underlay applicator option

• Ensure that sufficient paper is available for entire spread length

• Ensure that sufficient plastic overlay is available for entire spread length if plastic overlay is required forthe material to be cut

• Turn on the air floatation blower for the spreading table if available

• Transfer the leading edge of material from the spreading table to the conveyor cutting surface

• Ensure that the length of material is straight and parallel with the X-axis. The white bristle can be used asan edge guide. Material should normally be positioned a minimum of 100mm away from the operator sidedress plate

• Cover the leading edge of the spread material with plastic overlay

• Click on the E-Cut pull down menu and then select "turn vacuum on"

• Advance the material onto the conveyor cutting surface using the jog button located on the overlay toweror by selecting Material should be advanced such that it is close to the take-off end of the table in orderto verify proper material alignment and to insure that the underlay paper and overlay plastic cover theentire vacuum area

• After the material is advanced and positioned to the desired location, it is ready for cut

• Open the file to be cut in EasiSuite software

Warning

The maximum material thickness to be cut should not exceed 5 centimeters when compressed under vacuum.

Setup Procedure

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Setting up the Cut Parameters

The following machine and job parameters should be checked prior to starting a cut job:

• Knife reciprocating speed.• Knife sharpening frequency.• Cutting velocity.• Cutting acceleration.• General velocity.• General acceleration.• Cutting vacuum level.• Minimum vacuum level.• Lift and plunge angle.• Global fillet size.• Presser foot pressure.• Conveyor velocity.• Conveyor acceleration.• Cut-while-convey (on/off).• Common line removal (on/off).

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Instruction for Aligning, Cleaning and Replacing ConsumableParts

Replacement of Knife

Removing the Knife

1. Remove the thumb screw found on the front portion of tool head cover which secures the cover tothe tool head.

2. Carefully swing the tool head cover and move it upwards to ensure it is in upper position.3. Ensure that the reciprocating housing is in upper position.4. Using allen wrench release the two socket head cap screws from the top of the blade link.

5. Move the blade link upwards along with the coupler assembly and the knife.6. After the blade link, coupler assembly and knife are completely removed from the reciprocating housing,

holding the coupler, loosen the clamping bolt found on the top surface of coupler using allen wrench.NOTE: The screw will first become slightly lose and easy to turn, then it will become tight. Continue turning after it

tightens. It will then become lose again. After it loosens for the second time, the knife can easily beremoved.

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7. Pull the knife away from the coupler being careful to keep hands away from the sharp knife edge

8. Ensure that the removed knife is placed in a safe area because it contains sharp edges that posehazards.

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Replacing the Knife

1. Insert the new knife into the coupler.2. Ensure that the sharp edge of knife should face the direction of the spring plunger.3. Push the knife into the coupler until it stops. Make certain the knife is pushed past the ball

plunger detent.4. Tighten the clamping bolt.5. Lightly grease the outside diameter of the coupling assembly using Eastman No. 67-26324.6. Insert the knife along with the coupler and blade link from the top into the reciprocating housing. The

below picture shows the knife and coupler assembly installed in the upper, middle and lower knife guideassemblies. While holding the blade link gradually insert the knife along with the coupler into the reciprocating housing guide tube. Ensure that the back edge of knife is facing the lower knife back roller. (Thelower knife guide back roller can be seen by pressing down the spring loaded presser foot assembly).The tip of the knife should pass through the rectangular opening in the throat plate found on upper knifeguide. Ensure that the knife is kept in the vertical position so that the knife tip passes between the guiderollers found on the upper knife guide. Continue lowering the knife and coupler until the coupler engages the guide tube. Now at this point the knife and coupler are fully guided as it is lowered until the upperholes in the blade link match with the holes in lower arm.

7. After aligning the upper portion of blade link return the two socket head cap screws and secure it usingallen key.

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Replacement of Sharpening Wheels

Removing the Sharpening Wheels

1. Remove the thumb screw found on the font portion of tool head cover which secures the cover tothe tool head.

2. Carefully swing the tool head cover and move it upwards to ensure it is in upper position.3. Ensure that the reciprocating housing is in upper position.4. Using allen wrench release the two socket head cap screws from the top of the blade link.5. Move the blade link upwards along with the coupler assembly and the knife.6. After the blade link, coupler assembly and knife are completely removed from the reciprocating housing,

remove the rotating tool head assembly as per the instructions below.7. Disconnect all wires connected to intellicut.8. Hold the bottom of the rotating tool head in one hand and then release the screw which holds the rotating

tool head housing to the shaft.9. Now rotating tool head drops down.10. Using allen key remove the screws which hold the sharpening wheels and remove the worn-out

sharpening wheels.

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Replacing the Sharpening Wheels

1. Using a clean dry cloth saturated with alcohol clean the mounting surfaces of the sharpening housing.2. Apply a few drops of “Loctite 222 MS” on the end of screws which hold the sharpening wheels.3. Install the new sharpening wheels.4. Return the screws to hold the grinding wheels.5. Return the rotating tool head and ensure when you put back the tool head on the shaft the pin on the tool

head should be aligned to the key way on the shaft (ref image).6. Raise the tool head after alignment with keyway to upper position until it stops.7. Tighten the screw which holds the rotating tool head housing to the shaft.

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Replacement of Drill Rod

Removing the Drill Rod

1. Remove the thumb screw found on the font portion of tool head cover which secures the cover to the toolhead.

2. Carefully swing the tool head cover and move it upwards to ensure it is in upper position.3. Using the supplied chuck key turn counter clockwise to loosen the drill chuck.

4. After the drill chuck is loosened the drill rod will drop down.

5. Manually lift the drill pressure foot upwards until the drill rod is removable.

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Replacing the Drill Rod

6. Lift the drill pressure foot high enough to install the new drill rod.7. Insert the new drill rod through the drill bushing into the drill chuck.8. Hold the drill rod in one hand and tighten the drill chuck using the chuck key as required.

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Replacement of Guide Bushing

Removing the Guide Bushing

1. Remove the thumb screw found on the font portion of tool head cover which secures the cover to the toolhead.

2. Carefully swing the tool head cover and move it upwards to ensure it is in upper position.3. Using the supplied chuck key turn counter clockwise to loosen the drill chuck.4. After the drill chuck is loosened the drill rod will drop down.5. Manually lift the drill pressure foot upwards until the drill rod is removable.6. Using allen wrench loosen the set screw found on the drill pressure foot.

7. Using fingers push the drill bush from the bottom of the pressure foot and remove the worn-out guidebushing.

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Replacing the Guide Bushing

1. Install the new guide bushing into the hole of the drill pressure foot.2. Since the guide bushing has (4) different size holes align the correct size hole which matches the drill

rod.3. Rotate the guide bushing until the drill rod is aligned with the hole of the drill chuck.4. Tighten the set screw on the drill pressure foot and ensure that the drill rod is aligned with the hole in the

guide bushing.5. Tighten the drill chuck after the drill rod is aligned and inserted correctly.

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Replacement of Vacuum Filter

Removing the Vacuum Filter

1. Using flat head screw driver remove the screws which hold the filter box cover plate.

2. Remove the wing nut which holds the filter cover on filter housing.

3. Remove the filter cover from mounting stud.

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4. Slide filter cartridge from the filter housing.

5. Shake the cartridge over an open garbage can.

6. Using clean dry compressed air blow out filter until clean.

7. Replace with new filter if required based on inspection.

Replacing the Vacuum Filter

1. Install a new filter.

2. Using vacuum cleaner remove all debris found inside the filter chamber.

3. Return the cleaned filter cartridge and cover the filter housing.

4. Inspect the seal found on the filter box cover for any damage and repair as required.

5. Carefully return the filter box cover plate to the machine and secure it using the mounting screws.

6. Cover the cutting surface with polythene plastic and start the vacuum pump. Check the vacuum level inthe software and inspect for any audible leaks. Repair any leaks found.

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Replacement of Bristle Block

Removing the Bristle Block

1. Advance the conveyor to expose damaged bristle.

2. Apply E-stop to prevent the conveyor and gantry movement for safely.

3. Using a pair of pliers grab the bristle of the bristle block to be removed and pull from its aluminum slot.

Replacing the Bristle Block

1. Install the new bristle block by ensuring that the tab alignment is proper according to the slatarrangement on the aluminum slat. (refer image).

2. Apply pressure on the surface of bristle block so that the mounting tabs snap in the slat found with in thealuminum slat.

3. Release the E-stop allowing conveyor and gantry movement and advance conveyor and inspect theremaining bristle block and replace damaged bristles as required by following the above procedure.

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Replacement of Polythene Rolls

Instructions

1. Two persons are required one on either side of the machine.

2. Lift up the bar which holds the plastic overlay tube and set it on flat surface.

3. Pull out the bar from tube and insert into a new roll.

4. Replace the bar on tower and thread under the elevation bar as required.

Launching a Cut

• Open the file to be cut in the eSuite Software.

• Verify that the start point and cut direction for all parts is correct for the file being cut.

• Send the cut file to gantry by pressing the “Cut” icon in the eSuite.

• Position the laser pointer on the material where you intend to begin the cut.

• Press the “Zero” button found on the right edge of UIT panel.

• Press the “Next” button on the right edge of UIT panel to begin cutting of material.

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Calibration Procedure

The calibration procedures are used to calibrate the machine so that each piece is cut to the correct shape and size.The calibrations are initially done at machine installation and should only need to be calibrated if there is a cuttingproblem or modifications done to the machine.

Order of Calibration

Checks before Calibration

• Clear all material from conveyor cutting surface• Open EasiSuite software and "Zero the Table"

Tools Required

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Maintenance operations to be carried out by operator

The maintenance operations should be carried out as per the guidelines/instructions mentioned within the servicemanual. Additionally maintenance operations should be performed safely using lockout / tag out procedures as required.

The replacement of consumable items can be performed by the operator with little disassembly. It is advised to schedulethe replacement of consumables during periods of machine idle time or as required.

In case of failure of any consumable item it is possible to interrupt the cut file, replace the failed item and resume thecut file. In this scenario the operator should follow the procedures as described within this section.

Inspecting the Safety Devices

Frequency: Weekly and when all major maintenance operations are performed

Tools Required: None

Maintenance condition: Fully powered with initiation of “eSuite Software”

Inspection Items

All safety features in the machine are designed to protect the operator through a combination of interruption of power,disabling of components and stopping of motion.

Emergency Stop Buttons (E-Stop)

There are six red emergency stop buttons located on the machine. One on either side of gantry and the remaining on allfour corners of the machine.

To check the functionality of E-Stop buttons, the following steps outline the procedure

a) The machine should be fully powered on with the “eSuite Software”

b) Push one of the E-Stop buttons, when activated the depressed button will be illuminated. Verify motorpower is shut off, amplifiers are disabled and outputs are reset

c) Pull the E-Stop button back to its operational position and re-enable the eSuite Software

d) Repeat step b and c for all the remaining E-Stop buttons

Pause Buttons and Stop Discs

The pause buttons share the same functionality with the sop discs. When activated they stop all motion. While themachine is paused the system continues to monitor positions so that software restart is possible.

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To check the functionality of Pause Buttons, the following steps outline the procedure.

a) The machine should be fully powered on with “eSuite Software” activated.

b) Load a file in the eSuite software, turn off the tool enable switch, send cut file to gantry and position thelaser pointer on the material to be cut, press “Zero” and “Next” button on the UIT panel and wait for themotion to begin.

c) Push one of the Pause buttons, when activated the depressed button will be illuminated. The machinewill enter a pause state.

d) To resume the cutting operation press “Next” on the UIT or press the green start button on the take-onpush button station.

e) Repeat step c and d for the remaining pause button.

To check the functionality of stop discs, the following steps outline the procedure.

a) The machine should be fully powered on with “eSuite Software” activated.

b) Push one of the stop discs, when it is pushed from either side it will pause the cutting action and thepause push button illuminates.

c) To resume the cutting operation the stop disc must be returned back to center, detented position andvisually confirm the same when the pause push button light turns off.

d) Repeat step b and c for the remaining Stop Discs.

Limit switches

The ‘X’ limit switches are found on the gantry side plate while the ‘Y’ limit switches are found in the Y-car. Thefunction of the limit switches is to prevent motion of the gantry outside the cutting area by interrupting the powersent to the amplifier. The ‘X’ limit switches are responsible for limiting the motion in ‘X’ direction, while the ‘Y’ limitswitches perform the same in the ‘Y’ axis.

To check the functionality of Limit switches, the following steps outline the procedure.

a) The machine should be fully powered on with “eSuite Software” activated.

b) Instruct the eSuite software to find the limit switches by clicking with mouse on the check limits icon

.

Warning

The Gantry will now move under its own power in a controlled fashion to find and establish both the ‘X’ and ‘Y’limits. The Gantry will travel the entire length of table as it looks for the limit switches. The Y-Car will also travelalong with the gantry looking for the limit switches.

If there are any abnormalities the computer will generate an error message, alerting the operator about theproblem.

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Maintenance of User Interface Electronics

Frequency: Weekly or as needed as per the machine environment

Tools Required: A soft cloth and alcohol based cleaning product and compressed air

Maintenance condition: When the machine is powered off

Instructions

• Clean regularly with a non abrasive, non-corrosive alcohol product on the following items

o Computer Monitoro Keyboardo Touch screen display (UIT)

• Using clean, dry compressed air blow out the filter found on the computer CPU

• The floor around the machine i.e. safety zones must be kept clean by regular use of vacuum cleanerand to eliminate dust and debris which would interfere with machine performance and filtration systems.

Maintenance of Gantry

Frequency: Weekly

Tools Required: Lint free cloth, compressed air, lubrication oil (for type refer to Service Manual) and grease gun

Maintenance condition: When the machine is powered off, lock out / tag out as required

Instructions

• Using clean, dry compressed air blow out the dust and debris from the top of the gantry

• Using oil saturated cloth wipe down and clean the ‘Y’ axis guide rails

• Move the Y-Car manually to the ‘Y’ positive and ‘Y’ negative limits inspecting the ‘Y’ rack and ensuringthat there are no damaged portions or tight spots

• Examine the Y-axis E-Chain for damage

• With tool head open gently move the Y car in the positive and negative slightly, while doing so look forthe movement of the large pinion pulley. If an audible clicking is heard and if the Y car moves withoutthe pulley rotating then there is excessive backlash. If there is no audible noise and there is no movement of Y car without rotation of pulley, then there is no backlash. If excessive backlash is found pleaserefer to service manual for adjustment and rectification.

• With the electronics cover open physically reach on the electronics tray and with fingers push on beltbetween the pinion pulley and motor pulley to deflect the belt. If the deflection is greater than ·¼” thenthere is excessive belt deflection and the belt must be tightened as per the instructions found in theservice manual.

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• Using oil saturated cloth wipe down and clean the ‘X’ axis guide rails

• Move the gantry manually to the ‘X’ positive and ‘X’ negative limits inspecting the ‘X’ rack and ensuring that there are no damaged portions or tight spots

• Reaching under the operator side plate, the large pinion pulley can be found. While holding the gantryin static position slightly rotate the large pinion drive pulley clockwise and counter clock wise andlisten for any audible click. In addition if there is pinion movement without gantry movement then thereis excessive back lash. If excessive back lash is found please refer to service manual for instructions.Repeat the same procedure for non-operator side plate.

• Remove the gantry operator side plate end cover from the gantry. Remove the six screws which holdthe UIT panel. Next you find the four screws that lock the swing out electronics tray.Remove these screws and swing open the electronics tray exposing the ‘X’ drive belt. Using fingerspush on the ‘X’ drive belt in the middle i.e. between the large and small pulley to cause the belt deflect.If the deflection is greater than 3/8" refer to service manual for adjustment instructions. Repeat thesame procedure for non-operator side end cover.

• Examine the X-axis E-Chain for damage

• Use grease gun to lubricate the X-axis linear bearings

• Using dry compressed air blow out and clean the electronic filter found on the electronics cover of YCar

• Using clean dry compressed air blow out any debris found under the electronics cover, around theamplifiers or power supplies.

• While doing the maintenance of this area inspect all wires for evidence of damage. Refer to servicemanual for repair and replacement instructions as required.

Maintenance of Cutting Surface

Frequency: Weekly or as required

Tools Required: Hand held vacuum (shopvac), Bristle comb

Maintenance condition: machine powered off, lock out / tag out as required

Instructions

• Using conveyor controls advance the cutting surface and inspect the bristle for damaged bristleblocks. Replace damaged bristle blocks as required. See service manual for procedure.

• Using a bristle comb rake through the bristle blocks holding the bristle comb about ¾” inside thebristle. This will pull up any large fiber trapped within the bristle blocks. Pull out whatever debris ispresent. Using the vacuum cleaner place the nozzle directly on the surface of bristle, this will pulloutany small debris which is present. Once the exposed bristle has been cleaned sufficiently power upthe electronics as required and advance the conveyor to the next area of cutting surface to be cleaned.

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• Inspect the edge seal for any damage either on the rubber seal or to the antifriction surface. If anyissues found please refer the service manual for repair or replacement of the edge seal.

• Inspect the front and rear bristle engagement fingers, any bent or broken fingers must be replaced asper the instructions in the service manual. Also clean and remove any debris trapped within thefingers.

• Check the vacuum performance by covering the entire cutting surface with plastic overlay. Turn on thevacuum and verify the vacuum pressure levels, listen for audible vacuum leaks in the frame structure,cover, and machine in general. Refer to service manual for repair instructions if required.

Maintenance of Tool Head

Frequency: Daily and weekly.

Tools Required: A soft cloth and alcohol based cleaning product.

Maintenance condition: machine powered off.

Instructions

• Dip the cloth in the cleaning product and clean the guides and more specifically the presser foot, thishas to be done daily in order to avoid the accumulation of dust and debris.

• When the tool head is removed and replaced after service, check the tightness of the screws of thetool head and also the screws fastening the tool head to the gantry.

779 Washington St., Buffalo, N.Y. 14203-1396 U.S.A. • (716)856-2200 • Fax (716)856-1140 or (716)856-2068Manufacturers of Eastman Cloth Cutting and Cloth Spreading Machines

Website: www.EastmanCuts.com ©2012 Eastman Machine Company Printed in U.S.A. 7/13

Technical DataEASTMAN Multi-Ply

Form E-539

Multi-Ply CutterMaximum Gantry Speed …………………. 40 in/sec (102 cm/sec)Maximum Conveyor Speed ……………… 8 in/sec (20 cm/sec)Cut Accuracy * …..….........................…… +/- 0.010 in (0.025 cm)Gantry Weight …………………………..… 260 lbs (118 kg)Machine Voltage …………....... 208/220/380/400/415/440/575 VAC,3 Phase 50/60 HzBlower Operating Voltage ……………….. 220/440 VAC, 3 Phase, 60HzMinimum Operating Pressure …………… 75 psiVolume of Air Service ……………………. 30 SCFM

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Information based on standard 78" wide machine size* Relative to type and quality of fabric, cutting speed, pulling mode operational settings.* Conveyor pull accuracy to +/- 1/16" (+/- 1.6 mm)

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